Combination Combustor and Burner

ABSTRACT

A system for combusting reactants. The system includes a low pressure combustor coupled to a low pressure line. Coupled to, and sitting atop the low pressure combustor is a high pressure combustor coupled to a high pressure line. The high pressure line is coupled to a flame arrester and an ignition source. The flame arrester is located a sub-sonic distance from the ignition source such that a flame arrester can be used as opposed to a flame detonator arrester. Further, the ignition source is retractable such that it can be removed, altered, repaired, etc., from the safety of the ground.

PRIORITY

This application claims priority to provisional application 62/074,034filed Nov. 2, 2014, the entirety of which is incorporated herein byreference.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to a system and method for an adjustableburner.

2. Description of Related Art

Burners are used to combust reactants such as fuel and an air mixture.Burners have many different applications. Thus, there is a need for anadjustable burner. Further, burners are often housed within a combustor.There is a need for an efficient, safe, and affordable combustor.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are setforth in the appended claims. The invention itself, however, as well asa preferred mode of use, further objectives and advantages thereof, willbe best understood by reference to the following detailed description ofillustrative embodiments when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a view of a burner in one embodiment with FIG. 1a being theside view and FIG. 1b being the top view;

FIG. 2 is a top perspective view of a burner in one embodiment;

FIG. 3 is a perspective view of the bottom of a burner in oneembodiment;

FIG. 4 is a flow chart of a series of burners used with tanks in oneembodiment;

FIG. 5 is a flow chart of a combination combustor in one embodiment.

DETAILED DESCRIPTION

Several embodiments of Applicants' invention will now be described withreference to the drawings. Unless otherwise noted, like elements will beidentified by identical numbers throughout all figures. The inventionillustratively disclosed herein suitably may be practiced in the absenceof any element which is not specifically disclosed herein.

Several embodiments of Applicants' invention will now be described withreference to the drawings. Unless otherwise noted, like elements will beidentified by identical numbers throughout all figures. The inventionillustratively disclosed herein suitably may be practiced in the absenceof any element which is not specifically disclosed herein.

FIG. 1 is a view of a burner in one embodiment with FIG. 1a being theside view and FIG. 1b being the top view. FIG. 2 is a top perspectiveview of a burner in one embodiment. FIG. 3 is a perspective view of thebottom of a burner in one embodiment. Referring to FIG. 1, FIG. 1depicts a burner shroud 110 coupled to a mixing tube 103 via a shroudconnector 103. Virtually any type of suitable material can be used forthese items. In one embodiment the burner tip and swirlers 102 comprise304 Stainless steel with a melting temperature of about 2600° F. In oneembodiment the Venturi and air damper, discussed below comprise aluminumwith a melting temperature of about 1200° F. FIG. 2 shows a perspectiveview of the burner. Referring now to FIG. 2, as depicted, the burner 100comprises one or more swirlers 102. A swirler 102, as used herein,refers to a flap which controls the amount and direction of air flow. Asdepicted, the swirl 102 comprises a planar shape. In operation, air ispulled upward through gaps between adjacent swirlers 102. In oneembodiment, the burner 100 comprises a low-swirl burner, but in otherembodiments the burner 100 comprises a high-swirl burner. Low-swirlcombustion is an aerodynamic flame stabilization method which results inlow emissions of nitrogen. The swirl is created by the swirlers 102.

The number and pitch of the swirlers 102 can vary. As depicted theburner 100 comprises nine swirlers 102 but this is for illustrativepurposes and should not be deemed limiting. The swirlers 102, in oneembodiment, are angled from about 0 to about 30 degrees relative to thehorizontal. A steeper angle results in more aggressive mixing of thereactants with the air introduced through the swirlers 102. Inoperation, as the reactants within the mixing tube 103 exit the mixingtube 103, this creates a pressure drop causing air to be pulled upwardthrough the swirlers 102.

The swirlers 102 are positioned between the centrally located mixingtube 103 and the larger burner shroud 110. The shroud 110 comprises aninner diameter and an outer diameter, and the mixing tube 103 has aninner and outer diameter. In one embodiment, and as depicted, the innerdiameter of the shroud 110 is greater than the outer diameter of themixing tube 103 resulting in a void. The swirlers 102 are located at thevoid. Thus, as depicted, the mixing tube 103 is fully encompassed andsurrounded by the shroud 110. In one embodiment, the width of theswirler 102 is approximately equal to the length of the void. The lengthof the void, as measured as the distance between the outer diameter ofthe mixing tube 103 and the inner diameter of the shroud 102 ranges fromabout 0.4 to about 0.65 inches.

In one embodiment, the swirlers 102 are coupled to both the mixing tube103 and the burner shroud 110. The swirlers 102 can be coupled via anymethod or device known in the art including welding, soldering, screws,etc. In one embodiment the swirlers 102 are fixed meaning they cannot bemoved. In other embodiments, however, the swirlers 102 are coupled so asto be adjustable. In this sense, the pitch of the swirlers 102 can beadjusted.

As depicted, the top end, the downstream end, of the mixing tube 103comprises one or more channels 101. As used herein, downstream andupstream refer to relative locations throughout the process. Adownstream process or part occurs after an upstream process or part.Thus, referring briefly to FIG. 1, the shroud 110 is downstream of themixing tube 103 because reactants move through the mixing tube 103 andexit in the shroud 110. The channels 101 in one embodiment extendthroughout the length of the mixing tube 103, whereas in otherembodiments the channels 101 do not extend throughout the length of thefeed line 103. In one embodiment the size and number of the channels 101determine the desired flow rate of the burner. The channels 101 breakthe flow into smaller channels, increasing the available surface area ofthe flow compared to if a single channel were utilized. The efficiencyof the burner is increased, due in part, to the increased surface area.Further, in one embodiment the channels provide a swirl which furtherincreases mixing and efficiency. In some embodiments the channels aredrilled at an angle to further increase swirl and increase dispersion.

Reactants, including fuel and air, are carried through the mixing tube103. When properly mixed, the reactants combust in the presence of aflame. In one embodiment, the mixing tube provides turbulent flow. Theflame can be provided with a pilot flame, a lighter, an igniter, etc. Amixing tube 103, as used herein, refers to any tube wherein reactantscan be mixed. As depicted, the mixing tube 103 is upstream of the shroud110 and downstream of the air intake adjuster 104. The mixing tube 103can comprise virtually any length, but in one embodiment, the mixingtube 103 comprises a length of between about 10 inches to about 14.5inches. The mixing tube 103 can comprise any diameter, but in oneembodiment the diameter ranges from about ½ of an inch to about 5inches. In one embodiment the mixing tube 103 comprises a diameter ofabout 1 and ¼ inch.

The reactants can comprise virtually any fuel. In one embodiment, and aswill be discussed in more detail, the fuel comprises fumes collectedfrom oil storage tanks. These fumes comprise volatile lights whichcollect in the headspace of storage tanks. In one embodiment the mixturecomprises one or more of the following: hydrogen sulfide, nitrogen,oxygen, methane, carbon dioxide, ethane, propane, iso-butane,iso-pentane, N-butane, N-pentane, 2,2 dimethyl butane, cyclopentane,2-methylpentane, 3-methylpentane, N-Hexane, methylcyclopentanes,benzene, cyclohexane, 2-methylhexane, 3-methylhexane,dimethylcyclopentanes, heptanes, N-heptanes, methylcyclohexane, toluene,octanes, N-octane, ethyl benzene, P-M-xylene, O-xylene, nonanes,N-nonane, decanes, N-decane, undecanes plus. In one embodiment, toalleviate the pressure from building on the tanks, the fuel in theheadspace is removed and burned in a burner.

Returning back to FIG. 2, FIG. 2 depicts the burner shroud 110. Theburner shroud 110 is the location at which the combustion occurs. Here,reactants from the mixing tube 103 are mixed with air which has beenintroduced through the swirlers 102 as discussed above. In oneembodiment, for complete combustion of a 1,000 btu natural gas with aspecific gravity of 0.65, the air to gas ratio of 10:1 is utilized. Inthis embodiment, this results in an oxygen to gas ratio of 2:1. Thisexample is provided for illustrative purposes only and should not bedeemed limiting. In one embodiment, a oxygen to reactant gas ratio of2:1 allows for a more complete reaction and breakdown. Accordingly, thisratio allows for a complete and less partial combustion reaction. As anexample, this ratio provides sufficient oxygen such that carbon dioxide,as opposed to carbon monoxide and NOx gas, is produced.

The burner shroud 110, in one embodiment, has a flared shape. This shapeallows for a spreading of the air gas mixture. Further, this shape has aminimal impact on efficiency.

As depicted, the burner shroud 110 is coupled to the mixing tube 103 viaa shroud connector 112. The shroud connector 112 can comprise any devicewhich couples the shroud 110 to the mixing tube 103 and can comprisethreads, screws, welding, soldering, etc. As depicted, the shroudconnector 112 comprises an elongated connector piece which is coupled toboth the shroud 110 and the mixing tube 103. As depicted, the shroudconnector 112 couples the outside perimeter of the shroud 110 to theoutside perimeter of the mixing tube 103. This allows the shroud 110 andmixing tube 103 to be connected in such a way as to leave a void betweenthe two pieces for the swirlers 102.

Referring back to FIG. 1, coupled to, and upstream from the mixing tube103, is a Venturi tube 114. A Venturi tube 114 is a reduced diameterpipe which results in a reduction in fluid pressure. The results in anincrease of velocity with a corresponding decrease in pressure. Theincrease of velocity also results in increased mixing. As statedpreviously, the increased mixing results in increased burner efficiency.

As depicted in FIG. 1, upstream of the Venturi tube 114 is the gassupply 115. The gas supply 115 supplies gas and other reactants to theburner 100. In one embodiment the gas supply 115 is coupled to theheadspace of tanks, which will be discussed in more detail below. Theupstream gas supply 115 is coupled to the downstream gas coupler 106.The gas coupler 106 can comprise any pipe or tubing which connects theburner 100 to the gas supply 115. In one embodiment the gas supplyranges from about 10,000 to about 250,000 SCFD (thousand standard cubicfeet per day). In one embodiment, each burner has a capacity of betweenabout 10,000 to about 50,000 SCFD. These flow rates are for illustrativepurposes only and should not be deemed limiting.

As depicted, the gas coupler 106 has at least one air inlet 105. An airinlet 205 is any opening on the body of the gas coupler 206 throughwhich air can be entrained. Air that enters through the air inlet 105 issubsequently mixed with the other reactants in the mixing tube 103. Asdepicted the air inlet 205 is not located on the end of the gas coupler106 but is instead located on the body of the gas coupler 106. The sizeof the air inlet 205 can vary.

FIG. 3 is a perspective view of the bottom of a burner in oneembodiment. As depicted in FIG. 3, the air inlet 205 comprises twoopposing air inlets 205, each on one side of the gas coupler 206. In oneembodiment the air inlet 205 extends through the gas coupler 206 suchthat air can be pulled into the air inlet 205 and subsequently mixedwith the reactants within the mixing tube 103. Put differently, in oneembodiment the air inlet 205 is a void which extends from the outerdiameter of the gas coupler 206 to the inner diameter of the gas coupler206. The pressures, in one embodiment, range from about 0 to about 1psi.

In one embodiment the size of the air inlet 205 can be controlled withan air intake adjuster 204. An air intake adjuster 204, as used herein,refers to any device which changes or alters the size of the air inlet205. In one embodiment the air intake adjuster 204 comprises a sleevewhich moves along the length of the gas coupler 106 to adjust the sizeof the air inlet 205. As depicted, the air intake adjuster 204 comprisesa threaded sleeve which is coupled to external threading located on thegas coupler 206 and/or the Venturi 114. As can be seen, by rotating theair intake adjuster 204, the threaded sleeve advances along the lengthof the gas coupler 206, increasing or decreasing the size of the airinlet 205. While the air intake adjuster 104 is depicted as beingthreaded, this is for illustrative purposes only and should not bedeemed limiting. In other embodiments, for example, the air intakeadjuster 204 can be slidably adjusted and secured in place with a pin,screw, or the like. In other embodiments the air intake adjustercomprises a pivoting gate covering the air inlet 205 which can bemanipulated to control the size of the air inlet 105. Virtually any airintake adjuster 204 which can be manipulated along the length of the gascoupler 106 can be utilized.

In one embodiment, the air intake adjuster 204 comprises a lockingdevice 113, depicted in FIG. 1, which locks the air intake adjuster 204in the desired location. A locking device 113 prevents the air intakeadjuster 204 from undesirably moving and changing the size of the airinlet 205. The locking device 113 can comprise a set screw, a bolt, anut, or other device which secures the air intake adjuster 204 in place.

By changing the size of the air inlet 205, the ratio of air to fuelmixture can be fine-tuned and controlled. If more air or oxygen isneeded, the size of the air inlet 205 can be increased by adjusting theair intake adjuster 204. By better controlling the ratio of air to fuel,the efficiency of the burner can be increased and adjusted. In oneembodiment the air intake adjuster 204 is manipulated by hand to controlthe size of the air inlet 105. In other embodiments, however, the airintake adjuster 204 is automated. In such an embodiment the air intakeadjuster 204 can be coupled to a sensor such that the automated airintake adjuster 204 can be adjusted in real-time depending on the burnerefficiency, the pressure on the tanks, etc.

There are several benefits with an adjustable air intake adjuster 204.First, as noted, is the ability to fine-tune and control the air to fuelratio mixture. This provides the ability to adjust and control theburner to meet a desired burner efficiency, reduce emissions, etc.

Second, the air intake adjuster 204, in one embodiment, can be easilyadjusted in place, even when the burners are installed. Put differently,the burners 100, in some embodiments, do not need to be removed to beadjusted. Rather, they can be adjusted in their installed position. Thisis a large benefit which reduces downtime, decreases labor expenses,etc. If, for example, the pressure from the gas supply 115 increased ordecreases, the air intake adjuster 204 can be adjusted, in-place, toaccount for the change in pressure. This can be accomplished while theburner 100 is installed. In one embodiment, the air intake adjuster 204can be adjusted while the burner is operating.

FIG. 4 is a flow chart of a series of burners used with tanks in oneembodiment. As depicted, FIG. 4 shows two tanks 407. A tank 407, as usedherein, refers to both operational tanks as well as storage tanks. Anoperational tank is a tank used during production or in the process of achemical, oil, or gas. An embodiment will be discussed utilizing storagetanks, but this is for illustrative purposes only and should not bedeemed limiting.

In one embodiment the storage tanks 407 store oil and/or gas until theoil and gas is ready to be shipped and/or piped. Produced oil or gas isthus stored, often temporarily, close to the rig. When oil, for example,sits, the volatile gases within the oil collect in the headspace 408 ofthe tanks. If the gases within the headspace 308 is not removed, thenthe pressure in the tanks 407 build. Tanks 407 generally have emergencypressure relief valves which open after a threshold pressure has beenmet. In many instances, the emergency relief valves open at very lowpressures, even at ounces of pressure. In one embodiment, the thresholdpressure is about 4 ounces. However, the emergency venting is to beavoided due to environmental as well as regulatory concerns.Consequently, in one embodiment, the gases collected in the headspace408 is removed and burned to alleviate the pressure in the tanks 407.

As depicted, the headspace 408 of the storage tanks 407 are directed toa header 409. The header 409 collects the gases and directs the gases tothe gas supply line 115. The gas supply line 115 directs the gas to acombustor 411 comprising at least one burner 100. A combustor 411 is atank or other structure which houses at least one burner. As depicted,the combustor 411 houses three burners 100. The number and size of theburners 100 will depend on the volume, pressure, and types of gasses tobe combusted. As depicted, the combustor 411 comprises three burners 100operating in parallel.

The burner 100 will operate as previously discussed. Because the burner100 comprises an air intake adjuster 104, the ratio of reactants to airfor each burner 100 can be independently adjusted. Thus, the ratio ofreactants to air can differ amongst the three depicted burners 100. Asnoted, if the pressure from the tanks 407 changes, the air intakeadjuster 104 for at least one burner 100 can be adjusted to compensate.The result is finely tuned burner. In one embodiment, the burner 100 hasa destructive efficiency of greater than 99.99%.

In some embodiments, there is a need for combusting both high pressureand low pressure reactants. FIG. 5 is a flow chart of a combinationcombustor in one embodiment. As depicted in FIG. 5, a high pressurecombustor 520 sits atop a low pressure combustor 521. The high pressurecombustor 520 is downstream of the low pressure combustor 521. A highpressure combustor 520 encounters comparatively higher pressures thanthe low pressure combustor. The high pressure line 519 supplies highpressure reactants to the high pressure combustor 520. The pressurewithin the high pressure line 519 can range from about 0 to about 120psi. In one embodiment the high pressure line 519 comprises a flarebecause it comprises an exposed flame.

The high pressure combustor 520 and the low pressure combustor canhandle very different volumes. As discussed, in one embodiment a 24 inchlow pressure combustor can handle a volume of about 100,000 SCFD, andthe 24 inch high pressure combustor can handle volumes of between 1 and6,000,000 SCFD. In one embodiment the high pressure combustor handlesvolumes of about 4,000,000 SCFD. In another embodiment the 18″ combustorcan handle volumes of about 25,000 SCFD and have a high pressureattachment that will flow 1.2 MMSCFD. Conversely, in one embodiment, thepressure in the low pressure line 409 which supplies reactants to thelow pressure combustor 521 ranges from about 0 to 1 psi. In oneembodiment the low pressure line 409 and the high pressure line 519originate from different sources. For example, in one embodiment the lowpressure line 409 is coupled to storage tanks whereas a high pressureline is coupled to production vessels or a gas sales line. The highpressure line can comprise reactants similar to the low pressure line,though usually a lower btu. Whereas the btu for a low pressure line istypically greater than 2,000, in one embodiment, the typical btu for ahigh pressure line is between about 1,200 and about 1,500.

In one embodiment, and as depicted, the low pressure combustor 521 andthe high pressure combustor 520 are fluidly connected. As used herein,fluidly connected refers to a coupling such that both combustors operateas if sharing the same outer housing. Fluidly connected includes onecombustor segmented into a high and a low pressure combustor. Fluidlyconnected also includes two separately manufactured combustors coupledsuch that gases and other fluids exiting the low pressure combustor 521can freely enter the high pressure combustor 520. As an example, in oneembodiment, and as depicted, the top of the low pressure combustor 521is open to the bottom of the high pressure combustor 520. In thismanner, air, reactants, combustion gasses, etc. from the low pressurecombustor 521 flow upward into the high pressure combustor 520.

In one embodiment, and as depicted, the high pressure combustor 520 isdirectly coupled atop the low pressure combustor 521. This arrangementprovides several benefits. First, gases from the low pressure combustor521 can flow more freely to the high pressure combustor 520 than if theywere directed through piping.

Second, this arrangement requires a reduced footprint than if the twocombustors were not vertically arranged. Having a reduced footprint isan environmental advantage in that less land is required. Further, oftenthe landowner desires to minimize the amount of land which is used fordrilling and production.

Third, this arrangement is cheaper than having two separate combustors.Typically, a concrete foundation must be installed for each combustor.Further, each combustor requires separate piping, valves, controls, etc.Combining two combustors as depicted in FIG. 5 eliminates many of theseredundancies, decreasing costs.

Fourth, a combination combustor is more efficient than separatecombustors. The low pressure combustor 521 produces off-gas. Thisoff-gas includes combusted reactants, un-burned reactants, air, andother chemicals. Even if the low pressure combustor 521 is highlyefficient, there will always remain some reactants which are notcombusted. The arrangement discussed herein allows some of theoff-gasses produced by the low pressure combustor 521 to be combusted inthe high pressure combustor 520. This provides an additional opportunityto incinerate off-gases, including un-combusted reactants, produced bythe low pressure combustor 521. As such, the combination combustor hasmany environmental benefits.

Referring back to FIG. 5, FIG. 5 depicts an adjustable air intake 516.An adjustable air intake 516 includes any device known to restrict orotherwise control the flow of air through an opening. As depicted, theadjustable air intake 516 comprises a louver. Thus, as depicted, theadjustable air intake 516 comprises one or more adjustable flaps. Theadjustable air intake 516 can be manually adjusted, or it can beautomated.

The adjustable air intake 516 allows the amount of air introduced intoboth the low pressure combustor 521 and the high pressure combustor 520to be controlled. The amount of air has an effect on the burnerefficiency, temperature, etc. In one embodiment the combustor isotherwise sealed. Accordingly, in one embodiment, the air intake 516 isthe only way through which air can be introduced to the combustor.

In one embodiment, and as depicted, the adjustable air intake 516 islocated slightly upstream from the burner 100 in the low pressurecombustor. Such a location allows the burner 100 in the low pressurecombustor 521 to pull air through the adjustable air intake 516. Thisallows the low pressure combustor 521 to obtain the benefit of theadjustable air intake 516. While the figure depicts a single air intakeadjuster 516, this is for illustrative purposes only and should not bedeemed limiting. In other embodiments, for example, the combinationcombustor comprises two or more air intakes 516.

As depicted, the combination combustor comprises an ignition source 517.As depicted the ignition source 517 is located at the burner of the highpressure combustor 520. Thus, as depicted, the ignition source 517 islocated near the top of the high pressure combustor 520. The ignitionsource 517 can comprise any device which provides a spark or a flame toprovide ignition for the combustion. The ignition source 517 cancomprise an ignitor which provides a spark which can subsequently causeignition of the flammable gasses. In other embodiments, the ignitionsource 517 comprises a pilot light which supplies a small fire. In otherembodiments the ignition source 517 comprises a continuous sparkignitor.

Ignition sources 517 are subject to fouling. The ignition sources 517can become plugged, worn, and otherwise malfunction. Due to theirlocation at the top of the combustor, previously, an operator would beforced to climb the combustor and remove, replace, or repair themalfunctioning ignition source 517. Because the combustor is operatingat very high temperatures, the operator would have to wait until thecombustor cooled before climbing. Consequently, this repair was unsafe,time consuming, and costly due to the downtime involved. Accordingly, asdepicted, the combination combustor comprises an ignition track 518which allows the ignition source 517 to be moveable along the length ofthe combustor. The ignition track 518 can comprise any track whichallows an object to move along its length. This includes flexiblesupport structures such as rope, wire, cables, etc. upon which theignition source 517 is hoisted and lowered. In other embodiments theignition track 518 comprises a rigid material such as a rigid track. Ineither embodiment, the ignition source 517 can be hoisted or loweredwith any device known in art, including but not limited to, a pulley,rope, wires, hydraulics, wench, etc.

An ignition source 517 moveable along a track provides several benefits.First, it removes the need for an operator to climb atop the combustorto make repairs. Thus, a moveable ignition source 517 increases safety.Second, a moveable ignition source 517 reduces downtime and accordinglyreduces the costs associated with downtime. As noted, previously anoperator had to allow the combustor to cool, climb atop the combustor,and make repairs. This required the combustor to shut down, at leasttemporarily. This causes other processes to shut down, causingsignificant costs and lost revenue. With a moveable ignition source 517,if the ignition source becomes faulty the operator simply lowers theignition source 517 along the track 518 and repairs or replaces the partas necessary. Thereafter, the ignition source 517 is hoisted upwardalong the track 518, and the combustor is ignited. A further benefit isthe safety associated with staying on the ground.

FIG. 5 depicts a pilot line 523 which couples the ignition source 517 tothe burner of the high pressure combustor 520. The pilot line 523 cansupply a combustable pilot gas to or from the ignition source 517. Thepilot line 523 can use reactants from the high pressure line 519, or thepilot line 523 can comprise a separate source (not shown). The pilotline 523 directs a flame to the burner of the high pressure combustor520.

As depicted, the combination combustor further comprises a flamearrester 522. A flame arrester 522 is a device fitted to piping or otherstructure whose function is to allow flow but prevent the transmissionof a flame. Thus, as seen in FIG. 5, the flame arrester 522 allowsupward flow to the high pressure combustor 520 but prevents a flame fromtraveling upstream of the flame arrester 522. As noted, the highpressure line 519 is often coupled to production tanks, storage tanks,etc. which often contain flammable materials. If a flame were allowed totravel upstream and reach the tanks, the result could be catastrophic.Accordingly, a flame arrester 522 prevents flames from traveling beyonda specified point in a process.

A flame arrester 522 as used herein is differentiated from a detonationflame arrester. In one embodiment, a flame arrester 522 is built towithstand sub-supersonic velocities. In one embodiment, a flame arrester522 is not approved for supersonic velocities. A detonation flamearrester, however, is an arrester which is built and approved towithstand extreme pressures that travel at supersonic velocities. In oneembodiment the combination combustor comprises a flame arrester, whereasin other embodiments the combination combustor comprises a detonationflame arrester.

A detonator flame arrester is comparatively much more expensive than aflame arrester 522. The materials and complexity required to stop flamestravelling at supersonic speeds necessitate a much higher price comparedto a sub-supersonic flame arrester. As but one example, a 3″ flamearrester costs approximately $300-500. Conversely, a 3″ detonation flamearrester costs approximately $3,000 to $5,000. Accordingly, there issignificant cost savings in utilizing a flame arrester.

In one embodiment, a flame arrester 522 is located adjacent to the highpressure combustor 520. Accordingly, in one embodiment, the flamearrester 522 is not located on the ground but is instead elevated. Inone embodiment the flame arrester 522 is located a sub-sonic distancefrom the ignition source 517 when the ignition source 517 is in itsoperating location or from the location of the flame. A sub-sonicdistance is a distance at which a blowback flame has not yet attainedsupersonic velocities. In one embodiment the sub-sonic distance is lessthan about 10 feet. Flames often increase in velocity during a blowback.Thus, controlling the distance between the ignition source 517, or thelocation of the flame, and the flame arrester 522 also controls thevelocity of the flame during a blowback. By limiting the distancebetween the ignition source 517, or the location of the flame, and theflame arrester 522, in one embodiment, to a sub-sonic distance, such as10 feet, the flame fails to reach supersonic velocities. As such, acomparatively lower grade arrester can be utilized. In one suchembodiment, a flame arrester 522 which is not rated for supersonicvelocities can be utilized. This results in significant capital costsavings. If an arrester was instead placed upon the ground, and notwithin the sub-sonic distance, then an arrester which is rated forsupersonic velocities must be utilized as the blowback flame would havethe time and distance to reach a supersonic velocity. As noted, such anarrested is much more expensive than a flame arrester 522 which is notrated for supersonic velocities.

While the invention has been particularly shown and described withreference to a preferred embodiment, it will be understood by thoseskilled in the art that various changes in form and detail may be madetherein without departing from the spirit and scope of the invention.

Additional Disclosure

-   Clause 1. A burner comprising:    -   a burner shroud coupled to an upstream mixing tube, wherein said        burner shroud comprises at least two swirlers;    -   a gas coupler upstream from said mixing tube, wherein said gas        coupler comprises at least one air inlet;    -   an air intake adjuster coupled to said gas coupler, wherein said        air intake adjuster is adjustable relative to said air inlet.-   Clause 2. The burner of any proceeding or preceding clause wherein    said burner comprises a low-swirl burner.-   Clause 3. The burner of any proceeding or preceding clause wherein    said mixing tube comprises channels.-   Clause 4. The burner of any proceeding or preceding clause further    comprising a Venturi located downstream of said mixing tube.-   Clause 5. The burner of any proceeding or preceding clause wherein    said air intake adjuster comprises a threaded sleeve.-   Clause 6. The burner of any proceeding or preceding clause wherein    said gas coupler is coupled to a gas supply.-   Clause 7. The burner of any proceeding or preceding clause wherein    said shroud comprises an inner diameter and an outer diameter, and    wherein said mixing tube has an inner and outer diameter, and    wherein said inner diameter of said shroud is greater than the outer    diameter of the mixing tube resulting in a void between the mixing    tube and the surrounding shroud.-   Clause 8. The burner of any proceeding or preceding clause wherein    said at least two swirlers are located in said void.-   Clause 9. A system for combusting reactants, said system comprising:    -   at least one burner, said at least one burner comprising:        -   a burner shroud coupled to an upstream mixing tube, wherein            said burner shroud comprises at least two swirlers;        -   a gas coupler upstream from said mixing tube, wherein said            gas coupler comprises at least one air inlet;        -   an air intake adjuster coupled to said gas coupler, wherein            said air intake adjuster is adjustable relative to said air            inlet;    -   at least one tank comprising a headspace;    -   a gas supply line coupling the headspace of said at least one        tank to the at least one burner, wherein said at least one        burner is downstream from said at least one tank.-   Clause 10. The system of any proceeding or preceding clause wherein    said at least one burner is located in a combustor.-   Clause 11. The system of any proceeding or preceding clause wherein    said burner comprises a 99.99% destruction efficiency.-   Clause 12. The system of any proceeding or preceding clause wherein    said system comprises between three and five burners.-   Clause 13. The system of any proceeding or preceding clause wherein    said burner comprises a low-swirl burner, and wherein said mixing    tube comprises channels.-   Clause 14. The system of any proceeding or preceding clause further    comprising a Venturi located downstream of said mixing tube.-   Clause 15. The system of any proceeding or preceding clause wherein    said air intake adjuster comprises a threaded sleeve.-   Clause 16. The system of any proceeding or preceding clause wherein    said gas supply line has a through put of between 25,000 and 250,000    SCFD.-   Clause 17. The system of any proceeding or preceding clause said air    intake adjuster is adjusted to achieve a 2:1 oxygen to reactants    ratio.-   Clause 18. The system of any proceeding or preceding clause further    wherein said at least one burner is located within a low pressure    combustor, and wherein said system further comprises a high pressure    combustor coupled to the top of said low pressure burner.-   Clause 19. The system of any proceeding or preceding clause further    comprising a flame arrester and an ignition source, wherein said    ignition source is retractable, and wherein said flame arrester is    within a sub-sonic distance of said ignition source.-   Clause 20. The system of any proceeding or preceding clause wherein    said shroud comprises an inner diameter and an outer diameter, and    wherein said mixing tube has an inner and outer diameter, wherein    said inner diameter of said shroud is greater than the outer    diameter of the mixing tube resulting in a void between the mixing    tube and the surrounding shroud, and wherein said at least two    swirlers are located in said void.-   Clause 21. A system for combusting reactants, said system    comprising:    -   a low pressure combustor coupled to a low pressure line;    -   a high pressure combustor, wherein said high pressure burner is        coupled to the top of said low pressure burner;    -   a flame arrester coupled to a high pressure line;    -   an ignition source coupled to said high pressure combustor.-   Clause 22. The system of any proceeding or preceding clause wherein    said low pressure combustor comprises at least one burner, wherein    said at least one burner comprises:    -   a burner shroud coupled to an upstream mixing tube, wherein said        burner shroud comprises at least two swirlers;    -   a gas coupler upstream from said mixing tube, wherein said gas        coupler comprises at least one air inlet;    -   an air intake adjuster coupled to said gas coupler, wherein said        air intake adjuster is adjustable relative to said air inlet.-   Clause 23. The system of any proceeding or preceding clause wherein    said low pressure combustor comprises between three and five    burners.-   Clause 24. The system of any proceeding or preceding clause wherein    said burner comprises a low-swirl burner, wherein said mixing tube    comprises channels, and further comprising a Venturi located    downstream of said mixing tube.-   Clause 25. The system of any proceeding or preceding clause wherein    said air intake adjuster comprises a threaded sleeve.-   Clause 26. The system of any proceeding or preceding clause wherein    said shroud comprises an inner diameter and an outer diameter, and    wherein said mixing tube has an inner and outer diameter, wherein    said inner diameter of said shroud is greater than the outer    diameter of the mixing tube resulting in a void between the mixing    tube and the surrounding shroud, and wherein said at least two    swirlers are located in said void.-   Clause 27. The system of any proceeding or preceding clause wherein    said flame arrester is within a sub-sonic distance of said ignition    source.-   Clause 28. The system of any proceeding or preceding clause wherein    said sub-sonic distance is less than about 10 feet.-   Clause 29. The system of any proceeding or preceding clause wherein    said ignition source is retractable.-   Clause 30. The system of any proceeding or preceding clause further    comprising a track.-   Clause 31. The system of any proceeding or preceding clause further    comprising an adjustable air intake.-   Clause 32. The system of any proceeding or preceding clause wherein    said high pressure combustor and said low pressure combustor are    fluidly connected.-   Clause 33. The system of any proceeding or preceding clause wherein    said low pressure combustor has a capacity of between about 25,000    and 250,000 SCFD, and wherein said high pressure combustor has a    capacity of between about 1,200,000 and about 4,000,000 SCFD.-   Clause 34. The system of any proceeding or preceding clause wherein    said high pressure combustor comprises a flare.-   Clause 35. The system of any proceeding or preceding clause wherein    said high pressure line has pressures between 1 to about 120 psi,    and wherein said low pressure line comprises a pressure between    about 0 to about 1 psi.-   Clause 36. The system of any proceeding or preceding clause wherein    said high pressure line is coupled to a production vessel or a gas    line whereas said low pressure line is coupled to storage tanks.

What is claimed is:
 1. A system for combusting reactants, said systemcomprising: a low pressure combustor coupled to a low pressure line; ahigh pressure combustor, wherein said high pressure burner is coupled tothe top of said low pressure burner; a flame arrester coupled to a highpressure line; an ignition source coupled to said high pressurecombustor.
 2. The system of claim 1 wherein said low pressure combustorcomprises at least one burner, wherein said at least one burnercomprises: a burner shroud coupled to an upstream mixing tube, whereinsaid burner shroud comprises at least two swirlers; a gas couplerupstream from said mixing tube, wherein said gas coupler comprises atleast one air inlet; an air intake adjuster coupled to said gas coupler,wherein said air intake adjuster is adjustable relative to said airinlet.
 3. The system of claim 2 wherein said low pressure combustorcomprises between three and five burners.
 4. The system of claim 2wherein said burner comprises a low-swirl burner, wherein said mixingtube comprises channels, and further comprising a Venturi locateddownstream of said mixing tube.
 5. The system of claim 2 wherein saidair intake adjuster comprises a threaded sleeve.
 6. The system of claim2 wherein said shroud comprises an inner diameter and an outer diameter,and wherein said mixing tube has an inner and outer diameter, whereinsaid inner diameter of said shroud is greater than the outer diameter ofthe mixing tube resulting in a void between the mixing tube and thesurrounding shroud, and wherein said at least two swirlers are locatedin said void.
 7. The system of claim 1 wherein said flame arrester iswithin a sub-sonic distance of said ignition source.
 8. The system ofclaim 7 wherein said sub-sonic distance is less than about 10 feet. 9.The system of claim 1 wherein said ignition source is retractable. 10.The system of claim 1 further comprising a track.
 11. The system ofclaim 1 further comprising an adjustable air intake.
 12. The system ofclaim 1 wherein said high pressure combustor and said low pressurecombustor are fluidly connected.
 13. The system of claim 1 wherein saidlow pressure combustor has a capacity of between about 25,000 and250,000 SCFD, and wherein said high pressure combustor has a capacity ofbetween about 1,200,000 and about 4,000,000 SCFD.
 14. The system ofclaim 1 wherein said high pressure combustor comprises a flare.
 15. Thesystem of claim 1 wherein said high pressure line has pressures between1 to about 120 psi, and wherein said low pressure line comprises apressure between about 0 to about 1 psi.
 16. The system of claim 1wherein said high pressure line is coupled to a production vessel or agas line whereas said low pressure line is coupled to storage tanks.